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FEFCO 0218

Heavy-Duty Tuck-Top Box with Full Overlap Base

  • Available in a wide range of custom configurations & material selection.
  • Order 1 sample. Or order 100K+ units. Or anything in between.
  • Affordable delivery across North America.
  • Design support, warehousing, testing, assembly available.
  • Widest machinery capability in America via 30+ specialist partner plants.
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Product details

Top highlights

  • Double-thick floor supports heavy payloads and resists drop blowouts
  • Ear-hook tuck lid allows repeated tool-free opening and closing
  • Base flaps fully overlap and rely on tape, glue, or stitching for closure

About this product

This box merges two different packaging jobs. The bottom uses full overlap flaps to create a double-thick floor that supports heavy payloads, while the top uses a clean tuck-in lid with mechanical ear hooks for tool-free opening.

Because it combines a heavy-duty base with a presentation-style lid, it consumes more corrugated board than a standard shipping carton and requires shaped die-cutting. It fits situations where the product is heavy enough to risk blowing out a standard base, but the end user still needs a premium or repeatable unboxing experience.

Common uses

  • Reusable in-plant parts bins
  • Heavy presentation kits and sales samples
  • High-end consumer electronics
  • Industrial spare parts shipping

Get a quote

Share what you know. We'll take it from there. Or email us at info@herculeindustrial.com

Best Price Guarantee

Already have a packaging quote? Let us beat it.

Send us the quote you have. We will beat it for the same specifications, quantity, and delivery requirements.

Upload a competing quote

Free quote review. No obligation.

30+specialist partner plants

We supply through the plant best suited to your price, material, production, and delivery requirements.

Why we can beat a lower quote

30+ plants give us more ways to lower the price.

Each plant has different machinery, material costs, order minimums, and freight rates. Our buying volume helps us secure better pricing. We then quote through the plant that gives you the lowest total price for your requirements.

Send us your current quote. Watch us beat it.

Attach it to the quote form or email it to us. We'll review it free and send you our price.

Upload a competing quoteinfo@herculeindustrial.com
Best Price Guarantee terms

To qualify, send a written supplier quote dated within the past 30 days and addressed to your company. It must cover the same dimensions, construction, material, print, finish, quantity, tooling, freight, delivery date, and delivery location. The guarantee does not cover taxes, expired quotes, liquidation or clearance sales, or obvious pricing errors.

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Heavy-duty presentation and reusable storage

Reusable in-plant parts bins

The double floor handles the weight of metal components, while the ear-hook lid lets operators open and close the bin repeatedly without cutting tape.

Heavy presentation kits

When shipping heavy sample sets or sales kits, the base prevents the contents from dropping through, and the clean top keeps the unboxing experience focused on the product.

Large-format flat goods

When configured with a very low height, the double-thick base provides rigid protection for large posters, drawings, or flat components that cannot be folded.

High-weight retail electronics

Heavy amplifiers or power supplies benefit from the drop protection of the full overlap base while preserving a clean friction-tuck lid for the retail buyer.

Industrial parts, premium consumer goods, and media

Industrial manufacturing and kitting

Teams moving heavy components between facilities rely on the full overlap base for drop protection, often adding die-cut handles to the side panels for easier lifting.

High-end consumer electronics

Brands packing heavy items use this style to prevent the product from breaking through the bottom during retail handling, while preserving a clean unboxing experience.

Print and media distribution

Distributors shipping large, flat, fragile items use the rigid double floor to prevent bending, while the tuck top allows easy access without damaging the contents.

When a standard base or taped top makes more sense

If the unboxing experience does not matter

Compare the FEFCO 0203. It uses the same double-thick base but closes with standard taped flaps at the top, reducing board waste and shaped cutting requirements.

If the payload is relatively light

Compare the FEFCO 0212. It keeps the clean tuck top but uses a standard meeting-flap base, which consumes far less corrugated board.

Close variants and lookalike dielines

The closest library neighbors include 0203a, 0205a, 0206a. Use this as a variant check if a buyer brings an old code, sample, or dieline that looks close. The deciding details are usually the lock, slot, closure, wall build, part count, or fold sequence.

Board thickness, lock tension, and carrying handles

Board thickness versus lock tension

Fine flutes create crisp, reliable ear hooks but offer less base cushioning. Heavy double-wall board provides massive drop protection but can crush the ear hooks unless the cutting die is specifically tuned with wider lock gaps.

Base sealing method

The factory glues the side seam, but the packing team must seal the heavy bottom flaps. Heavy-duty tape, industrial glue, or stitching all work, but the choice affects packing speed.

Adding carrying handles

Because this box is often used for heavy items, die-cut hand holes are a common addition to the side panels. These should be specified early so they can be included in the cutting die.

Outer sealing for parcel networks

The ear-hook lid relies on friction. If the box will tumble through a courier network, plan for an outer tape seal or strap to keep the lid closed.

Handle cutouts, lock gaps, and tuck depth

Lock gap relief

The space around the ear hooks can be widened to accommodate thicker board grades, preventing the lid from binding or tearing during insertion.

Tuck flap depth

The length of the front tuck flap can be extended to provide more friction against the front wall, reducing the chance of the lid popping open.

Die-cut carrying handles

Hand holes can be cut directly into the side panels to help users lift the heavy payloads this box is designed to carry.

Board and packing details

Flat delivery size and production routing

The combination of a full overlap base and an attached full-size lid creates a very large unfolded blank. This requires flatbed or rotary die-cutting rather than simple straight-knife slotting, and the knocked-down boxes will take up more pallet space than standard cartons.

Carrying handle additions

Die-cut carrying handles

Often added to the short side panels to help users lift the heavy payloads this box is designed to carry.

Additional notes

Print surface and unboxing

The unbroken top lid provides a large, flat canvas for branding or instructions that the user sees immediately upon opening.

Storage space before use

Because the base flaps are full-length, the knocked-down flat box takes up more pallet space than a standard shipping box of the same internal volume.

Alternative heavy-duty and tuck-top boxes

FAQs

Shipping and route

Can this box ship through parcel networks without tape?

The ear-hook lid is designed for friction retention, not rough courier handling. If shipping via parcel, the top lid usually needs an outer tape seal or strap to prevent it from popping open during tumbling.

Production and routing

Does this box require shaped die-cutting?

Yes. The complex shape of the ear hooks and the tuck lid means this box must be die-cut, which involves a different production route than a standard rectangular shipping box.

Packing and closure

How is the bottom sealed?

The packing team must seal the full overlap base using tape, hot melt glue, or heavy-duty stitches before loading the product.

Board and material

Can we use heavy double-wall board?

Yes, but the cutting die must be adjusted. Thick board can cause the ear hooks to bind or crush. The lock gaps and fold allowances must be tuned specifically for the chosen board caliper.

Modifications

Are carrying handles standard?

They are a very common addition because the full overlap base encourages heavy payloads, but they must be specified before the cutting die is made.

Packing labor

Does this save packing time?

It saves time for the end user opening the box, but the initial packing team still has to square the box, fold the heavy base flaps, and seal the bottom.

Storage and handling

Does this box take up more space before use?

Yes. Because the base flaps are full-length, the knocked-down flat box takes up more pallet space than a standard shipping box of the same internal volume.

Print and finish

Is the top lid a good surface for printing?

Yes. The unbroken top lid provides a large, flat canvas for branding or instructions that the user sees immediately upon opening.